Modifiers for aqueous basic solutions of phenolic resole resins

Abstract

The subject invention relates to modifiers for aqueous basic solutions of phenolic resins. The modifiers are open-chain ether alcohols or ketone alcohols. They assist in stabilizing the aqueous basic solutions of phenolic resole resins and improve the tensile strength of foundry shapes prepared from foundry mixes made with the aqueous basic solutions.

We claim: 
     
       1. A binder composition comprising: A. an aqueous basic solution of a phenolic resole wherein said aqueous basic solution has 1. a viscosity of less than about 850 centipoise at 25? C.;   2. a solids content of about 35 to about 75 percent by weight, said weight based upon the total weight of the basic solution; and   3. an equivalent ratio of base to phenol of about 0.2:1.0 to 1 1:1.0; and     B. a modifier selected from the group consisting of open-chain ether alcohols, ketone alcohols, and mixtures thereof, wherein said modifier is used in an amount of at least 1.0 weight percent based upon the weight of the aqueous solution of phenolic resole resin.   
     
     
       2. The binder composition of claim 1 wherein the modifier is an ether alcohol. 
     
     
       3. The binder composition of claim 2 wherein the phenolic resole resin is prepared by reacting formaldehyde and phenol in a mole ratio of formaldehyde to phenol of about 1.1:1.0 to about 2.2:1.0 in the presence of an effective amount of a basic catalyst at elevated temperature of about 50° C. to about 120° C. 
     
     
       4. The binder composition of claim 3 wherein the equivalent ratio of base of phenol used in preparing the aqueous basic solution is from 0.3:1.0 to 0.95:1.0. 
     
     
       5. The binder composition of claim 4 wherein the base is selected from the group consisting of sodium hyrdoxide, potassium hydroxide, and mixture thereof. 
     
     
       6. The binder composition of claim 4 where the viscosity of the phenolic resin is from less than about 450 centipoise at 25° C. 
     
     
       7. The binder composition of claim 6 where the ether alcohol is used in an amount of about 3 weight percent to about 10 weight percent, said weight percent based upon the weight of the aqueous basic solution. 
     
     
       8. The binder composition of claim 6 where the ether alcohol is used in an amount of about 5 weight percent to about 7 weight percent, said weight percent based upon the weight of the aqueous basic solution. 
     
     
       9. The binder composition of claim 8 wherein the ether alcohol is selected from the group consisting of triethylene glycol ether and diethylene glycol butyl ether. 
     
     
       10. A foundry mix comprising: A. a foundry aggregate; and   B. an effective binding amount of the binder composition of claim 1.   
     
     
       11. A foundry mix comprising: A. a foundry aggregate; and   B. an effective binding amount of the binder composition of claim 2.   
     
     
       12. A foundry mix comprising: A. a foundry aggregate; and   B. an effective amount of the binder composition claim 3.   
     
     
       13. A foundry mix comprising: A. a foundry aggregate; and   B. an effective binding amount of the binder composition of claim 4.   
     
     
       14. A foundry mix comprising: A. a foundry aggregate; and   B. an effective binding amount of the binder composition of claim 5.   
     
     
       15. A foundry mix comprising: A. a foundry aggregate; and   B. an effective binding amount of the binder composition of claim 6.   
     
     
       16. A foundry mix comprising: A. a foundry aggregate; and   B. an effective binding amount of the binder composition of claim 7.   
     
     
       17. A foundry mix comprising: A. a foundry aggregate; and   B. an effective binding amount of the binder composition of claim 8.   
     
     
       18. A foundry mix comprising: A. a foundry aggregate; and   B. an effective binding amount of the binder composition of claim 9.   
     
     
       19. A process for preparing a workable foundry shape comprising: A. injecting the foundry mix of claim 10 into a corebox or pattern mold;   B. curing said foundry mix with an volatile ester until a workable shape is formed.   
     
     
       20. The process of claim 19 wherein the ester is a C 1  to C 4  alkyl formate. 
     
     
       21. The process of claim 20 wherein the ester is methyl formate. 
     
     
       22. A workable foundry shape prepared according to claim 19. 
     
     
       23. A process for forming a metal casting comprising: A. forming a workable foundry shape according to claim 19;   B. pouring molten metal into or around said shape;   C. allowing said metal to cool and soldify; and   D. removing the metal casting.   
     
     
       24. A metal casting formed in accordance with claim 23. 
     
     
       25. A process for preparing a workable foundry shape comprising: A. injecting the foundry mix of claim 11 into a corebox or pattern mold;   B. curing said foundry mix with a volatile ester until a workable shape is formed.   
     
     
       26. A process for preparing a workable foundry shape comprising: A. injecting the foundry mix of claim 12 into a corebox or pattern mold;   B. curing said foundry mix with a volatile ester until a workable shape is formed.   
     
     
       27. A process for preparing a workable foundry shape comprising: A. injecting the foundry mix of claim 13 into a corebox or pattern mold;   B. curing said foundry mix with a volatile ester until a workable shape is formed.   
     
     
       28. A process for preparing a workable foundry shape comprising: A. injecting the foundry mix of claim 14 into a corebox or pattern mold;   B. curing said foundry mix with a volatile ester until a workable shape is formed.   
     
     
       29. A process preparing a workable foundry shape comprising: A. injecting the foundry mix of claim 15 into a corebox or pattern mold;   B. curing said foundry mix with a volatile ester until a workable shape is formed.   
     
     
       30. A process for preparing a workable foundry shape comprising: A. injecting the foundry mix of claim 16 into a corebox or pattern mold;   B. curing said foundry mix with a volatile ester until a workable shape is formed.   
     
     
       31. A process for preparing a workable foundry shape comprising: A. injecting the foundry mix of claim 17 into a corebox or pattern mold;   B. curing said foundry mix with a volatile ester until a workable shape is formed.   
     
     
       32. A process for preparing a workable foundry shape comprising: A. injecting the foundry mix of claim 18 into a corebox or pattern mold;   B. curing said foundry mix with a volatile ester until a workable shape is formed.